PCBA Process Engineer

Insight Global; Austin (TX); On-site; USD 95,000 - 130,000; Full time

Benefits offered by this job

Healthcare benefits

401(k) or equivalent

Job summary

Insight Global seeks a senior manufacturing professional to lead PCB fabrication and PCBA production processes. You will own process development, qualification, and continuous improvement across SMT, reflow, wave soldering, and test-related controls in a high-volume environment.

You will drive manufacturing readiness for new product introductions, partnering with design engineering, quality, test, operations, and supply chain to optimize capability, capacity, and cost.

Qualifications

• Bachelor's degree in a related technical field.
• Extensive process engineering experience in PCB fabrication/PCBA in high-volume production.
• Strong knowledge of IPC workmanship standards, ESD controls, and quality systems.

Responsibilities

• Own and improve PCB fabrication and PCBA production processes including SMT and test-related controls.
• Monitor throughput, cycle time, yield, scrap, and downtime to maximize production performance.
• Lead root-cause investigations and corrective actions for defects and complex issues.
• Plan and execute equipment, process, material, tooling, and product qualifications.
• Lead manufacturing readiness for new products and ramp-up initiatives with cross-functional teams.
• Define and maintain process parameters, SOPs, work instructions, and process flow maps.
• Develop jigs, fixtures, stencils, and tooling to improve stability and deposition quality.
• Drive Lean/Six Sigma projects to increase utilization and reduce defects.
• Support equipment lifecycle, preventive maintenance, calibration, and spare parts.
• Coordinate with suppliers on equipment and services; assist with quoting and approvals.
• Provide technical guidance across production, engineering, quality, and supply chain.

Skills

PCB fabrication

SMT assembly

Process engineering

Root cause analysis

Lean Six Sigma

Data analysis

Project leadership

Cross-functional collaboration

Education

Bachelors in Electrical/Mechanical/Manufacturing/Industrial/Materials Engineering

Tools

MES/ERP platforms

MS Office

Data visualization tools

Job description

Job Description

Duties and Responsibilities

• Production Process Leadership: Own, develop, document, and continuously improve PCB fabrication and PCBA production processes, including SMT, solder paste printing, component placement, reflow, wave/selective soldering, cleaning, inspection, and test-related process controls.
• FE Production Performance: Ensure front-end production output and maximum equipment utilization are achieved at expected quality and cost by monitoring throughput, cycle time, downtime, capacity, yield, scrap, and rework performance.
• Root Cause and Corrective Action: Lead structured root cause investigations and corrective actions for FE defects and complex PCBA issues, including solder defects, placement errors, opens, shorts, tombstoning, bridging, contamination, insufficient wetting, and delamination.
• Equipment and Product Qualification: Plan and execute equipment, process, material, tooling, and product qualifications; establish acceptance criteria, validate capability, document results, and support release to production.
• NPI and Mass Production Readiness: Lead manufacturing readiness for new product introduction and production ramp-up, partnering with design engineering, quality, test, operations, and supply chain on DFM reviews, process validation, risk reduction, product qualification, capacity, and scalable production controls.
• Process Controls and Documentation: Define and maintain critical process parameters, control plans, SOPs, work instructions, process specifications, process flow maps, risk assessments, FMEAs, and production standards to ensure repeatable and compliant operations.
• Tooling, Jigs, and Stencils: Develop, review, qualify, and continuously improve jigs, fixtures, pallets, carriers, and SMT stencils to strengthen process stability, solder paste deposition quality, manufacturability, ergonomics, and repeatable production performance.
• Continuous Improvement: Lead Lean, Six Sigma, and data-driven improvement projects that increase equipment utilization and throughput, improve line balance, reduce cycle time and defects, and identify sustainable cost-reduction opportunities.
• Equipment Lifecycle Support: Evaluate and implement production equipment and technologies, establish preventive maintenance, calibration, verification, and spare-parts requirements, and partner with maintenance and suppliers to resolve equipment-related constraints.
• Supplier and Vendor Coordination: Coordinate with external suppliers on equipment, tooling, materials, services, and technical deliverables; support quotation reviews, purchase documentation, and timely processing of approved vendor payment requirements.
• Cross-Functional Leadership and Compliance: Provide technical guidance to production and engineering partners, drive actions to closure, and ensure processes meet internal standards, customer requirements, IPC workmanship criteria, ESD controls, environmental requirements, and applicable safety regulations.

Skills and Requirements

• Education: Bachelor's degree in Electrical, Mechanical, Manufacturing, Industrial, Materials Engineering, or related technical field.
• Senior-Level Manufacturing Experience: Substantial process engineering experience in PCB fabrication, PCBA, SMT assembly, or electronics manufacturing within a high-volume production environment, including ownership of complex production issues and improvement initiatives.
• PCBA Process Expertise: Advanced working knowledge of solder paste printing, component placement, reflow profiling, wave/selective soldering, cleaning, inspection, rework, and test-related process controls.
• Quality and Reliability: Strong knowledge of IPC workmanship standards, ESD controls, quality systems, statistical process control, process capability, control plans, and electronics manufacturing best practices.
• Analytical Problem-Solving: Demonstrated ability to analyze SPC trends, first-pass yield, equipment utilization, capacity, defect Pareto data, scrap, rework, and downtime to determine root causes and implement sustainable corrective actions.
• Improvement Methods: Hands-on experience using 5 Why, fishbone diagrams, 8D, DMAIC, FMEA, Lean, and Six Sigma methods to lead measurable process improvements.
• NPI and Qualification: Experience leading manufacturing readiness, DFM reviews, process validation, equipment and product qualification, risk assessment, and high-volume production ramp-up.
• Equipment and Tooling: Experience qualifying production equipment and developing or improving SMT stencils, tooling, fixtures, jigs, pallets, and carriers, including maintenance, calibration, verification, and spare-parts considerations.
• Technical Documentation: Ability to create and control clear SOPs, work instructions, process specifications, flow maps, qualification reports, troubleshooting guides, and manufacturing control documentation.
• Software and Data: Proficiency with Microsoft Office and experience with manufacturing systems, statistical analysis tools, MES/ERP platforms, or data visualization tools used for process monitoring and decision-making.
• Leadership and Collaboration: Strong communication, project leadership, and cross-functional collaboration skills, with the ability to influence production, quality, test, maintenance, supply chain, design engineering, headquarters teams, and external suppliers.
• Production Support: Ability to manage multiple priorities in a fast-paced manufacturing environment, respond to urgent production needs, make sound technical decisions, and drive actions to closure with minimal supervision.

We are a company committed to creating diverse and inclusive environments where people can bring their full, authentic selves to work every day. We are an equal employment opportunity/affirmative action employer that believes everyone matters. Qualified candidates will receive consideration for employment without regard to race, color, ethnicity, religion, sex (including pregnancy), sexual orientation, gender identity and expression, marital status, national origin, ancestry, genetic factors, age, disability, protected veteran status, military or uniformed service member status, or any other status or characteristic protected by applicable laws, regulations, and ordinances. If you need assistance and/or a reasonable accommodation due to a disability during the application or the recruiting process, please send a request to [e-mail].